JPH09155827A - Manufacture of concrete product having irregular-shape plate material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing concrete products wherein respective raised faces of irregular surfaces can be matched up even in a case of large-size tiles having irregular surfaces. SOLUTION: In a molding concrete form 3, a plurality of ceramic tiles 2 having irregular surfaces are arranged upside down at specified intervals. The rear faces of the ceramic tiles 2 are made to be contact faces to a concrete material. Next, the concrete material is injected into the molding concrete form 3 and cured so as to integrally arrange the ceramic tiles 2 on a surface of a formed concrete. In between the surfaces of the ceramic tiles 2 and the molding concrete form 3, mats 1 which can be used repeatedly are arranged. The irregular patterns of the mats 1 are meshed with the irregular patterns of the ceramic tiles 2, so that the rear faces of the ceramic tiles 2 are positioned on almost the same plane.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a concrete product with an irregular shaped plate material.

[0002]

2. Description of the Related Art Conventionally, the following method has been used to drive a tile or a stone material having a flat surface onto a concrete surface. That is, first, as shown in FIG.
The tiles 31 and the like are laid on the bottom of the form 32 in an appropriate pattern and laid out, and then the filling material 33 such as sponge is filled in the gaps between the tiles 31 and the like.
Sealing material 34 on the top of the ceiling to a certain height (tile 31
Etc.) to less than the thickness). Next, a concrete material is poured from the upper end opening of the mold 32, and after the curing and curing of the concrete material, the filler 33 is removed, and the seal material 34 is left on the removal trace, which is formed on the joint portion, Manufacture concrete products with tiled surfaces.

[0003]

However, in the above method, the tile 31 or the like is large (for example, the size is 600 cm × 600 cm or more), and the surface thereof has unevenness such as split skin. When the pattern 31a is present, even if an attempt is made to drive this into a precast concrete plate (PC plate) for a building or the like, as shown in FIG. It was not located on the same plane), so it was very difficult in terms of manufacturing method. Therefore, the large tiles 31 and the like having the concavo-convex pattern 31a formed on the surface are not actually used for the PC board. Moreover, when the tiles 31 are laid on the bottom of the form 32 or when concrete material is placed, the tiles 31
There is also a problem that the concavo-convex pattern 31a on the surface is easily damaged. In the case of the large tile 31, for example, the tile 31
Since there is a difference in the heat shrinkage force between the concrete material and the concrete material, there is a problem that the tile 31 or the concrete is cracked due to the difference in the heat shrinkage force.

The present invention has been made in view of such circumstances, and even in the case of a large tile having an uneven surface, the projected surface of each uneven surface can be aligned, and the uneven surface can be arranged when laying the tiles. The purpose of the present invention is to provide a method for producing a concrete product with an irregularly shaped plate material that will not be damaged.

[0005]

In order to achieve the above object, the present invention is to form a plurality of irregular shaped plate materials having an uneven surface in a molding form for injecting a concrete material with a predetermined gap in an inverted state. Arrange, arrange the joint forming member in each gap, make the back surface of the irregular shaped plate material a contact surface for the concrete material, then inject the concrete material into the forming mold to cure and form the irregular shaped plate material on the concrete surface. A method of manufacturing a concrete product with an irregular shaped plate material to be integrated and arranged, wherein, between the surface of each irregular shaped plate material and the portion of the molding frame facing this, the uneven surface of each irregular shaped plate material By arranging a mat that can be used repeatedly with the corresponding uneven surface and engaging the uneven surface of each irregular plate material with the uneven surface of each mat, the back surface of each irregular plate material is located on substantially the same plane. A configuration that was Unishi.

That is, the present invention provides a plurality of irregularly shaped plate materials having uneven surfaces such as large tiles, a mat which can be repeatedly used having uneven surfaces corresponding to the uneven surface of each irregularly shaped plate material, and concrete material injection. When manufacturing a concrete product with an irregularly shaped plate material using a molding die for molding, the mat is arranged between the surface of each of the irregularly shaped plate materials and the portion of the molding frame that faces the irregularly shaped plate material. By engaging the uneven surface of each mat with the uneven surface of each irregular plate, the back surface (outer surface) of each irregular plate is positioned on substantially the same plane. Therefore, each irregular shaped plate material does not tilt in the molding frame, and the protruding surface of the irregular surface of each irregular shaped plate material matches, and even if it is a large ceramic tile having an irregular surface, it can be used as a PC plate for buildings, etc. Can be adopted. Moreover, since the mat plays the role of a cushioning member,
The irregular surface of the irregular shaped plate material is not damaged when arranging the irregular shaped plate materials in the forming frame or when placing the concrete material. Also, after the mounting bracket is detachably locked to the back surface of the irregular shaped plate material, the elastic adhesive layer is formed in a state where the mounting portion of the mounting bracket can project, and the concrete material is poured in contact with this elastic adhesive layer. In this case, even if there is a difference in heat shrinkage force between the irregular-shaped plate material and the concrete material, the contractive force is absorbed by the elastic adhesive layer, so that the irregular-shaped plate material and the concrete are not cracked. Then, the fixing of the irregular shaped plate material to the concrete, since the portion of the mounting metal fitting protruding from the elastic adhesive layer is embedded in the concrete,
It is done firmly. In the present invention, the part of the molding frame on which the mat is arranged may support the mat.
Therefore, the part of the molding form is not limited to the bottom part of the box-forming form frame that is open at the top, but a square frame-shaped molding form,
It also includes the part of the base surrounded by the square frame when placed on a base such as the earth.

Next, the present invention will be described in detail.

Examples of the material of the amorphous plate material used in the present invention include stone materials and ceramic tiles. As the material of the ceramic tile, natural materials such as clay, porcelain stone, silica stone, feldspar, alumina, zirconia, silicon carbide,
Examples of the synthetic raw material include silicon nitride, and clay is preferably used. A color close to that of natural stone may be forcibly expressed by partially mixing different pigments into such a ceramic style. It is also conceivable to add a foam material. An irregular pattern such as a split surface is formed on the surface of such an irregular shaped plate material.

As the material of the mat used in the present invention, various materials are used, and a castable material is preferably used. In particular, urethane rubber, silicone rubber, butyl rubber and the like are listed. This mat is molded so that it can be used repeatedly. In addition, the same number of such mats as the above-mentioned irregular-shaped plate material is prepared, and an uneven pattern corresponding to the uneven pattern of each irregular-shaped plate material is formed on the surface of each mat. The number of mats can be limited to the same number (that is, several types) as the number of patterns by limiting the number of patterns of the irregular pattern of each irregular plate material to several.

As the material of the joint forming member used in the present invention, a caulking material (which is in contact with the concrete material) and its backup material are used. An elastic adhesive is used as the caulking material, and a rubber rod (foamed styrene joint backup material) is used as the backup material.

As the mounting bracket used in the present invention, various mounting brackets are used.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION Next, an embodiment of the present invention will be described with reference to the drawings.

FIG. 1 shows an embodiment of the method of the present invention. In the figure, reference numeral 1 is a mat having an uneven pattern formed on the front surface 1a and a flat surface on the back surface. The same number of mats as the ceramic tiles 2 shown in FIG. 2 are prepared. Each of these ceramic tiles 2 has an uneven pattern such as a split surface on the front surface 2a, and the back surface is formed as a flat surface. The uneven pattern of each mat 1 is formed in a shape corresponding to a part of the uneven pattern of each ceramic tile 2. First, the mats 1 are arranged face up on the iron bottom plate 3a of the molding frame 3. Then, as shown in FIG.
The ceramic tile 2 is placed on the mat 1 with the surface facing down, and the uneven pattern on the surface 1a of the mat 1 is matched with the uneven pattern on the surface 2a of the ceramic tile 2. In this state, the ceramic tile 2 is lowered to engage the two. It is done. As a result, the back surfaces of the ceramic tiles 2 are substantially flush with each other, and a predetermined gap is provided between the ceramic tiles 2. The ceramic tile 2 is formed with a pair of grooves 2b (only two positions are shown in the figure) at four positions on the back, front, back, left and right. Next, as shown in FIG. 3, anchor fittings 4 (mounting fittings) are attached to the four grooves 2b on the back surface of each ceramic tile 2. Alternatively, before mounting each ceramic tile 2 on each mat 1, the anchor metal fittings 4 may be attached to the four grooves 2b on the back surface of each ceramic tile 2, respectively.

As shown in FIGS. 4 to 6, each of the anchor metal fittings 4 has a plate-like main body 5 in which a central portion is bent and formed in a gate shape, and both side portions are bent inward and inclined downward. A pair of mounting plates 6 that are bent and formed in an L shape and are disposed on both sides of the gate-shaped bent portion 5a of the main body 5, both side walls of the gate-shaped bent portion 5a of the main body 5, and lower portions of the pair of mounting plates 6. A bolt 7 inserted into the holes 5c and 6a formed in the hole 7, a rotation stop plate 8 arranged on the threaded portion of the bolt 7, and a washer 9 are provided, and even when the bolt 7 is screwed in, a pair is formed. The mounting plate 6 is configured to be able to slightly swing with respect to the bolt 7. Then, the pair of inward bent portions 5b on both sides of the main body 5 are engaged with the pair of grooves 2b of the ceramic tile 2, and the pair of mounting plates 6 are embedded in concrete. When attaching such an anchor metal fitting 4 to the groove 2b on the back surface of the ceramic tile 2, the bolt 7 is loosened and the main body 5 of the anchor metal fitting 4 is attached to the ceramic tile 2 while adjusting the tightening amount of the bolt 7. Attach the inwardly bent portion 5b. In this mounted state, the pair of mounting plates 6 can swing with respect to the bolts 7. Therefore, even if the concrete contracts due to thermal expansion, the pair of mounting plates 6 moves following the contraction of the concrete. It can absorb the contraction force.

After the anchor metal fitting 4 is attached to the ceramic tile 2, as shown in FIG. 7, the gap between the ceramic tiles 2 is filled with the backup material 10 and the caulking material 11 is filled thereon. The elastic adhesive 12 is applied to the back surface of the ceramic tile 2. Next,
As shown in FIG. 8, the concrete material 13 is filled from the upper opening of the molding frame 3, and after curing and curing, the backup material 10 is removed from the concrete surface, and then the mold is removed.
This gives the desired concrete product. A plurality of ceramic tiles 2 are decorated on the surface of the concrete product thus obtained.

As described above, in the above embodiment, the ceramic tiles 2 are placed upside down on the mat 1 and the back surfaces of the respective ceramic tiles 2 are flush with each other.
The projecting surface of the ceramic tile 2 fits the molding frame 3, and the ceramic tile 2 does not tilt. Moreover, since each mat 1 functions as a cushioning member, the uneven pattern of the ceramic tile 2 is not damaged when the ceramic tiles 2 are lined up on the iron bottom plate 3a of the molding frame 3 or when the concrete material 13 is cast. . Furthermore, joints can be formed by the caulking material 11, and the caulking material 11
Can prevent concrete material 13 from entering,
The concrete material 13 does not adhere to the surface of the ceramic tile 2 during pouring. Also, concrete material 1
3, the ceramic tile 2 is attached to the ceramic tile 3 by using the mounting bracket 4, the contracting force of the concrete material 13 can be absorbed by the mounting bracket 4, and the ceramic tile 2
Since the coating layer of the elastic adhesive 12 is formed on the back surface of the ceramic tile 2, the ceramic tile 2 and the concrete material 13 are not cracked.

[0017]

As described above, according to the method for producing a concrete product with an irregular shaped plate material of the present invention, the irregular shaped plate materials arranged in the forming frame do not tilt, and the irregular surface of each irregular shaped plate material is not inclined. Even a large-sized ceramic tile having a protruding surface and an uneven surface can be used as a PC board for buildings and the like. Since the mat functions as a cushioning member, the uneven surface of the irregular shaped plate material is not damaged when the irregular shaped plate materials are lined up in the molding frame or when the concrete material is cast. Also, after the mounting bracket is detachably locked to the back surface of the irregular shaped plate material, the elastic adhesive layer is formed in a state where the mounting portion of the mounting bracket can project, and the concrete material is poured in contact with the elastic adhesive layer. In this case, even if there is a difference in heat shrinkage force between the irregular-shaped plate material and the concrete material, the contractive force is absorbed by the elastic adhesive layer, so that the irregular-shaped plate material and the concrete are not cracked. Then, the fixing of the irregular shaped plate material to the concrete is performed firmly because the portion of the mounting metal fitting projecting from the elastic adhesive layer is embedded in the concrete.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing a manufacturing process of a concrete product of the present invention.

FIG. 2 is an explanatory view showing a manufacturing process of the concrete product.

FIG. 3 is an explanatory view showing a manufacturing process of the concrete product.

FIG. 4 is a side view of a mounting bracket used in the present invention.

FIG. 5 is a front view of the mounting bracket.

FIG. 6 is a perspective view of components of the mounting bracket.

FIG. 7 is an explanatory view showing a manufacturing process of the concrete product.

FIG. 8 is an explanatory view showing a manufacturing process of the concrete product.

FIG. 9 is an explanatory diagram of a conventional example.

FIG. 10 is an explanatory diagram of another conventional example.

[Explanation of symbols]

 1 mat 1a surface 2 ceramic tile 2a surface 3 molding form 4 mounting bracket 13 concrete material

Claims (2)

[Claims] 1. A mold for injecting concrete material, wherein a plurality of irregularly shaped plate materials having an uneven surface are lined up with a predetermined gap in an inverted state, and a joint forming member is arranged in each gap, and the irregular shape is formed. A method for producing a concrete product with an irregular shaped plate material, in which the back surface of the plate material is made into a contact surface with the concrete material, and then the concrete material is poured into the above-mentioned forming mold and hardened , Between the surface of each of the irregular shaped plate material and the portion of the molding frame that faces the irregular shaped plate material, a repeatable mat having an uneven surface corresponding to the uneven surface of the irregular shaped plate material is provided. Concrete with irregular shaped plate material, characterized in that the back surface of each irregular shaped plate material is located on substantially the same plane by engaging the uneven surface of each mat with the uneven surface of each irregular shaped plate material. How to make a product. 2. An elastic adhesive layer is formed in such a manner that the mounting portion of the mounting member can be projected after the mounting metal member is detachably locked to the back surface of the irregular shaped plate material, and the concrete is contacted with the elastic adhesive layer. The method for producing a concrete product with an irregular shaped plate material according to claim 1, wherein the material is injected.